Detailed Project Report (DPR) on toughened and laminated glass

TOUGHENED AND LAMINATED GLASS

[CODE NO.4171]  

Main Types of Glass

Today, flat glass comes in many highly specialized forms intended for different products and applications. Flat glass produced by way of the float process is often further processed (see below) to give it certain qualities or specificities. In this way, the industry can meet the various requirements and needs of the construction, automotive and solar-energy industries:

• Annealed glass

• Toughened glass

• Laminated glass

• Coated glass

• Mirrored glass

• Patterned glass

• Extra-Clear glass

Toughened Glass

Toughened or tempered glass is a type of safety glass processed by controlled thermal or chemical treatments to increase its strength compared with normal glass. Tempering puts the outer surfaces into compression and the inner surfaces into tension. Such stresses cause the glass, when broken, to crumble into small granular chunks instead of splintering into jagged shards as plate glass (a.k.a. annealed glass) creates. The granular chunks are less likely to cause injury.

As a result of its safety and strength, toughened glass is used in a variety of demanding applications, including passenger vehicle windows, shower doors, architectural glass doors and tables, refrigerator trays, mobile screen protectors, as a component of bulletproof glass, for diving masks, and various types of plates and cookware.

Toughened glass, as the name itself suggests, is glass material is tougher than ordinary glass that has low resistance power. These are stronger varieties that are used in various places, whether residential or commercial constructions. In fact, the strength of the toughened glass is up to five times more than that of annealed glasses. Toughened glass is also used to manufacture glassware and these products are comparatively safer and offer more durability. However, the strength of these items should not be confused with any wrong perception of being unbreakable. If products made of toughened glass are handled with proper care, they can last even for a lifetime.

Annealed glass is heated above 720°C, which is the highest annealing point and after the extreme heating procedure, rapid cooling is conducted with air. Taking the surface lower than the annealing point cools off the glass. This causes the surface to become hard and contracts while the core still flows for a while. Finally, the core cools into numerous layers under tensile stress, balanced by compressive surface stresses. Because of these stresses, the toughened glass is strong and tough. However, a scratch on the surface or even a small cheap can weaken the layer and sometimes it may lead to breaking into small pieces.

There is an alternative process of creating toughened glass, which is done by using certain chemicals. Here the surface layer of the glass needs to be forced at least 0.1mm thick into compression by the exchange of sodium ions in the surface of the glass with the potassium ions that are larger by 30%, by immersing the glass into a molten potassium nitrate mixture. This chemical process of making toughened glass results in more toughness.  This process of manufacturing can be used with complex shaped glass objects.

Toughened glass items have wide usage. Where the chances of damage and stress are high, this glass variety is used. Typical usages of this glass include counter tops, shelves, glass table tops, doors, window panels, window glazing, etc. Therefore, it is suitable for use in residential and commercial purposes.

Toughened glass is a type of soda-lime-silica glass with a sheet thickness 4-12 mm.  The sheet has a central tensile stress of 500-1200 kg/cm2 and a ratio of surface compressive stress to central tensile stress of 2:1 to 4:1. The article is toughened by heat exchange with an oil (or chilled air) in which these are maintained from 0.01 - 0.07 % liquid. The boiling point liquid may be an organic liquid such as carbon tetrachloride, methanol, benzene, toluene, trim ethyl alcohol, ethyl alcohol or Xylene etc.

The toughened glass is described as a type of glass which has been mechanically strengthens by a thermal process in which a layer of compression has been introduced at the surface.

There are several glass items introduced into early ages of the century.

Toughened safety glass (float or polished) is produced by subjecting glass to a process of heating and rapid cooling so  as to induce high compressive stresses in the surface sones balanced by  high tension in the central place. This treatment endows the glass with greatly increased resistance to external forces, such as mechanical loading and thermal shock. If toughened safety glass is fractured, it gives fragments which are less liable to cause severe cuts than fragments of ordinary glass.

Thus toughened safety glass, if fractured, disintegrates into small pieces and in addition, its liability to fracture under the action of external forces or changes of temperature is greatly reduced.

Characteristics of Toughened Glass

Toughened glass is four to five times stronger than annealed glass of the same size and thickness against impact. Toughened glass has higher thermal strength and can withstand a high temperature differential upto 250°C.Toughened glass is considered as safety glass. It is difficult to break and even in the event of a breakage, disintegrates into small globules, which are relatively harmless.

Toughening does not alter the basic characteristics of glass such as light transmission and solar radiant heat properties.

After heat treatment, the surface of toughened glass has the same resistance to surface damage as annealed glass. Toughened glass cannot be cut, drilled or altered.

Heat soak test is recommended to be carried out on Toughened glass that is used for overhead and horizontal application, to prevent the spontaneous breakage caused due to nickel sulphide inclusion.

COST ESTIMATION

Plant Capacity                                     636.36 sq.mt./Day

Land & Building (6000 sq.mt.)           Rs. 3.53 Cr

Plant & Machinery                                Rs. 4.83 Cr

Working Capital for 2 Months             Rs. 2.77 Cr

Total Capital Investment                      Rs. 12.15 Cr

Rate of Return                                       54%

Break Even Point                                   41%

• INTRODUCTION
• MAIN TYPES OF GLASS
• TOUGHENED GLASS
• CHARACTERISTICS OF TOUGHENED GLASS
• PROPERTIES OF TOUGHENED GLASS
• ADVANTAGES:
• BENEFITS:
• STRENGTH & SAFETY CONSIDERATIONS
• TYPICAL BREAKAGE PATTERN
• RESISTANCE TO THERMAL BREAKAGE
• THERMAL BREAKAGE PATTERN
• TYPICAL BREAKAGE PATTERN
• PROPERTIES
• MECHANICAL PROPERTIES OF TOUGHENED GLASS
• USES AND APPLICATION
• APPLICATIONS OF TOUGHENED GLASS
• LAMINATED GLASS
• USES AND APPLICATIONS OF LAMINATED GLASS
• APPLICATION OF LAMINATED GLASS
• B.I.S. SPECIFICATION
• PROCESS FLOW DIAGRAM
• MANUFACTURING PROCESS OF TOUGHENED GLASS
• GLASS CUTTING
• GLASS POLISHING:
• DRILLING & MILLING
• GLASS WASHING
• TOUGHENING
• PROCESS OF TOUGHENED GLASS IN DETAILS
• GLASS CUTTING
• GLASS POLISHING
• DRILLING AND MILLING
• GLASS WASHING
• TOUGHENING OR TEMPERING
• TOUGHENING PROCESS
• WASHING AND DRYING
• TESTING
• FLOW SHEET
• PROCESS OF MANUFACTURE FOR LAMINATED SAFETY GLASS
• SAFETY LAMINATION:-
• FORMULATION
• MARKET POTENTIAL
• UK TEMPERED GLASS MARKET DEMAND, BY APPLICATION, 2012-2022
• (MILLION SQUARE METERS)
• OVERVIEW OF GLOBAL GLASS MARKET
• PLANT LAYOUT
• PRINCIPLES OF PLANT LAYOUT
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE 
• SERVICE ARE:
• PLANT LOCATION FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• 6. TRANSPORTATION:
• 7. WASTE DISPOSAL:
• 8. LABOR:
• 9. REGULATORY LAWS:
• 10. TAXES:
• 11. SITE CHARACTERISTICS:
• 12. COMMUNITY FACTORS:
• 13. VULNERABILITY TO WARTIME ATTACK:
• 14. FLOOD AND FIRE CONTROL:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• SUPPLIERS OF TOUGHENED GLASS
• SUPPLIERS OF LAMINATED GLASS
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF GLASS SHEET
• SUPPLIERS OF PVB SHEET
• SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)
• SUPPLIERS OF SURFACE GRINDING MACHINE
• SUPPLIERS OF GLASS POLISHING MACHINE
• SUPPLIERS OF GLASS DRILLING MACHINE
• SUPPLIERS OF GLASS CUTTING MACHINES
• SUPPLIERS OF LATHE MACHINE
• SUPPLIERS OF DG SETS
• SUPPLIERS OF EOT CRANE
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF ELECTRIC MOTOR
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSORS
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• SUPPLIERS OF SHOT BLASTING MACHINE
• SUPPLIERS OF JIGS AND FIXTURE
• SUPPLIERS OF SUBMERSIBLE WATER PUMP

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)